Wittke StarLight User manual

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2935 C
Maintenance Manual

10/19/07 PART NUMBER: #90309
STARLIGHT™ & SUPERDUTY™
MAINTENANCE MANUAL

Part #: 90309 iii
Table of Contents
Maintenance
Liability ..................................................................................................... 1
Warning .................................................................................................... 1
Lifting Components for Service ............................................................. 1
Lifting the Arms and Forks ........................................................ 2
Lifting the Front Body ................................................................ 2
Lifting the Entire Body ............................................................... 4
Prior to Hydraulic System Maintenance ................................................ 6
Hydraulic Settings and materials ........................................................... 7
System Settings: ....................................................................... 7
Welding Information ................................................................................ 7
Lubrication ............................................................................................... 8
Centralized Grease Block ......................................................... 9
Packer Rails Lubrication ......................................................... 10
Maintenance Checklist .......................................................................... 11
Electrical System ................................................................................... 34
Electrical Schematics .............................................................. 34
How the Electrical System Works ........................................... 34
Control Panel (located centrally in the cab) ................................ 34
Relay Box (located in the cab) .................................................... 35
Electronic Controller .................................................................... 35
Proximity Switches ...................................................................... 36
Harnesses ................................................................................... 36

iv Part #: 90309
Adjusting and Repairing Electrical Components ............................... 36
Circuit Breakers and Fuses ..................................................... 37
Fuses .......................................................................................... 37
Manual Reset Circuit Breakers ................................................... 37
Adjusting the Proximity/Limit Switch Settings ......................... 39
Proximity Switches on the Street Side ........................................ 40
Proximity Switches on the Curb Side .......................................... 40
Lever Arm Limit Switches ....................................................... 41
Proximity Switch Gap Adjustment ........................................... 41
Packer Fully Retracted Proximity Switch ................................ 42
Packer Fully Extended Proximity Switch ................................. 43
Side Access Door Limit Switch ............................................... 45
Top Door Fully Open Proximity Switch ................................... 46
Tailgate Unlocked Proximity Switch ........................................ 46
Tailgate Fully Open Proximity Switch ..................................... 47
Arms Partially Raised Proximity Switch .................................. 47
Arms and Forks Fully Retracted Proximity Switch ................. 50
Body Raised Limit Switch (optional) ....................................... 53
Pneumatic System ................................................................................ 54
How the Pneumatic System Works ......................................... 54
Air supply .................................................................................... 54
Filter System ............................................................................... 54
In-Line Lubricator (optional) ........................................................ 55
Controls ....................................................................................... 55
Outside Controls ......................................................................... 55

Part #: 90309 v
Valve Box and Air Valves ............................................................ 56
Air Actuators ............................................................................... 57
Central Air Drain Cocks (optional) .............................................. 57
Pneumatic System Schematics .............................................. 58
Hydraulic System .................................................................................. 60
Hydraulic Oil Tank ................................................................... 60
Return Line Filter .................................................................... 61
Return Line Filter element ....................................................... 61
Routine Maintenance .............................................................. 61
Element Replacement Procedure ........................................... 62
Hydraulic Oil ............................................................................ 63
Recommended Lubricant ............................................................ 63
Hydraulic Pump ....................................................................... 63
Directional Control Valve ........................................................ 64
Pressure Relief Valve ............................................................. 64
Work Circuits ........................................................................... 65
Arms Up Deceleration Valve ................................................... 65
Pack Circuit Dump Valve ........................................................ 67
Pressure Switch ...................................................................... 67
Pressure Switch Adjustment ....................................................... 67
Timer Adjustment ........................................................................ 68
Tailgate Lock Valve ................................................................. 70
Service Hoist (optional) ........................................................... 71
Arms Down Work Section ....................................................... 72

vi Part #: 90309
Arms Down Deceleration Valve (optional) .............................. 72
Main System Pressure Adjustment ......................................... 74
Commercial Front Loader ........................................................... 74
Hydraulic Hose ........................................................................ 75
Hydraulic System Schematics ................................................ 76
Packer Maintenance .............................................................................. 80
Packer Wear Plates Replacement .......................................... 80
Body Guide Wear Plates Replacement .................................. 82
Packer Removal Procedure .................................................... 84
Packer Cylinder Replacement ................................................ 85

Part #: 90309 1
MAINTENANCE
LIABILITY
Labrie Environmental Group assumes no liability for any
incidental, consequential or other liability from the use of this
information. All risks and damages, incidental or otherwise,
arising from use or misuse of the information contained herein
are entirely the responsibility of the user. Although careful
precaution has been taken in the preparation of this material, we
assume no responsibility for errors or omissions.
WARNING
Prior to using your new STARLIGHT™ or SUPERDUTY™ Front
Loader, it MUST BE COMPLETELY LUBRICATED as shown on
the lube decal located near the rear of the body on the
passenger side. (Also see Lubrication section in the
Maintenance Checklist).
Initial lubrication carried out by Labrie Environmental Group is
sufficient for production and transport purposes ONLY!
With your safety in mind, we would like to remind you that ONLY
QUALIFIED PERSONNEL should service the hydraulic,
electrical, and pneumatic systems on your refuse vehicle. In
addition, these mechanics should be fully versed in the
operation of this unit. Please read the Operator Manual, prior to
attempting any maintenance of your Wittke Front Loader.
LIFTING COMPONENTS FOR SERVICE
Lifting components of the WITTKE requires special attention to
safety.
Before attempting these lifts:
•Emptythebody.
• Chock both the front and rear wheels.
•Standclearofanycranesorsimilarliftingdevices
when doing any lifts.
•Donotstandorwalkunderaloadthatissuspended
unless there are additional safety blocking devices
in place.

2Part #: 90309
While Labrie Environmental Group has included the
specifications of the lift equipment we use, these specifications
are intended as guides only. It is your responsability to ensure
your lift equipment meets all safety standards and that only
qualified personnel attempt these lifts.
LIFTING THE ARMS AND FORKS
You may need to lift the arms and forks manually. If you need to
do this, remember:
• If the forks cylinders are removed or disconnected,
the forks can rotate freely – tie each fork to the arms
before lifting the arms and forks assembly.
•Placealiftslingratedto6400lbs(2903kgs)inthe
middle of the fork pivot tube.
• Complete job, reconnect.
• Keep the sling in place while you repressurize the
system.
LIFTING THE FRONT BODY
Lifting the front body may be required when you need to
complete repairs.
You will need:
• A 18000-lb (8165 kgs) overhead crane
•Twoliftslingsratedto6000lbs(2722kgs)
• A 12000-lb (5443 kgs) lift beam
To raise the front body:
1. Raise the arms until they are resting on the rubber arm
stops on the sides of the body (stowed position) and
completely retract the forks against the arms.
CAUTION
IFBOTH ARM CYLINDERS ARE REPLACED, MOVE THE JOYSTICK BACK
AND FORTH IN GRADUALLY INCREASING INCREMENTS. THIS WILL
DISTRIBUTE THE OIL EVENLY WITHIN THE CYLINDERS AND PREVENT
THE ARMS FROM FALLING.

Part #: 90309 3
2. Remove the both outer grease fittings located on each
side of the arm pivot tube. That way, you won’t damage
the grease fittings or the lifting straps.
3. Securely attach the slings to the lift beam, which was
previoulsy installed on the overhead crane.
4. Wrap a lift sling around each end of the arm pivot tube.
5. Unlatch the body latches (one on each side).
6. Raise the front body. Do not raise the front body more
than 28 inches high.
7. Install proper safety props before performing maintenance
under a lifted body.
CAUTION
MAKE SURE THAT THERE IS ENOUGH CLEARANCE BEFORE LIFTING
THE BODY.
DANGER
ALWAYS USE PROPER LIFTING DEVICES AND SAFETY PROPS BEFORE
PERFORMING ANY MAINTENANCE TASK UNDER ALIFTED BODY.
FAILURE TO DO SO MAY RESULT IN SEVERE INJURY OR EVEN DEATH.
Outer grease
fitting
Lift sling

4Part #: 90309
LIFTING THE ENTIRE BODY
Note:All the ratings provided below are the minimum
values.
Lifting the WITTKE body requires securing both ends, front and
rear, to a lift beam. To do so, you will need two 3000-lb
(1361 kgs) rated slings (rear, see picture below), two 3000-lb
rated shackles (rear), two 6000-lb (2722 kgs) rated slings
(front), one 12000-lb (5443 kgs) lift beam (front), one 6000-lb lift
beam (rear) and one 18000-lb (8165 kgs) overhead crane. You
can also use a 12000-lb overhead crane at the front of the body
and one 6000-lb overhead crane at the rear.
1. Perform step 1 to step 5 of the Lifting the Front Body
section.
2. Install a 3000-lb shackle on both holes located on top of
the body, near tailgate hinges.
Shackle

Part #: 90309 5
3. Fasten shackles securely on each 3000-lb lift sling.
4. Securely attach the slings to the 6000-lb lift beam, which
was previoulsy installed on the overhead crane.
5. Lift the body. Make sure to raise both ends of the body at
the same time.
Lift
beam
Sling
Install shackle here

6Part #: 90309
PRIOR TO HYDRAULIC SYSTEM
MAINTENANCE
As with all hydraulic systems, it may be necessary to
periodically check and adjust the pressure relief settings. It may
be that a major hydraulic component has been changed, the
unit is not performing in terms of payload, or the unit has
recently been put into service and the system requires
adjustment following a run-in period.
Caution:
• The mechanic must have previous hydraulic knowledge as
serious injury or death can result from following improper
procedures.
• Human skin can be easily penetrated by high pressure oil
(2000 psi and above). Failure to take appropriate safety
precautions may result in serious injury or death.
• Also, there are extreme overhead dangers if equipment is
not properly supported when servicing areas on the
hydraulic system.
CAUTION
FOLLOW APROPER LOCKOUT/TAGOUT PROCEDURE PRIOR TO
SERVICING THE HYDRAULICS. DEATH OR SERIOUS INJURY CAN
RESULT. REFER TO THE OPERATOR MANUAL FOR MORE
INFORMATION ON SAFETY AND LOCKOUT/TAGOUT PROCEDURE.

Part #: 90309 7
HYDRAULIC SETTINGS AND MATERIALS
SYSTEM SETTINGS:
WELDING INFORMATION
MAIN PRESSURE
RELIEF VALVE (AT
1500 RPM)
2500 PSI AT 1500RPM
(STARLIGHT™)
2750 PSI AT 1500RPM
(SUPERDUTY™)
ARMS DOWN PORT
PRESSURE RELIEF
VALVE
1000 PSI
PRESSURE SWITCH IN
PACK CIRCUIT
2350 PSI AT 1500RPM
(STARLIGHT™)
2600 PSI AT 1500RPM
(SUPERDUTY™)
THROTTLE ADVANCE 1500 RPM
CAUTION
DISCONNECT ALL BATTERIES AND ELECTRONIC MODULES PRIOR TO
WELDING ON PACKER BODY.
CAUTION
REMOVE PAINT BEFORE WELDING OR HEATING. DONOT WELD NEAR
LINES THAT ARE PRESSURIZED OR CONTAIN FLAMMABLE FLUID.

8Part #: 90309
LUBRICATION
LUBRICATE, LUBRICATE, LUBRICATE! Insufficient lubrication
is a major cause of component failure. The Wittke front laoders,
like most equipment, have numerous points that require grease.
Refer to the lubrication chart located on the side of the truck for
a complete list of lube locations and the frequency they should
be greased.
# 120557

Part #: 90309 9
CENTRALIZED GREASE BLOCK
Pins at the packer end of the cylinders are remotely greased via
two grease fittings on the curb side front of the packer. Pins at
the front header end of the cylinders must be greased manually.
Grease fittings
Packer
Grease fittings
(view from inside
the hopper)

10 Part #: 90309
PACKER RAILS LUBRICATION
It is very important to lubricate packer rails, mainly on the
packing stroke area, in order to ensure their good condition. A
lubricant spray is provided with the truck (at back of the packer)
to perform this task.
Lubricant
spray
Lubricant
spray
Spray all lubricant on
both rails (mainly on
the packing stroke
area)

Part #: 90309 11
MAINTENANCE CHECKLIST
ITEM DESCRIPTION PRE-TRIP AT
LANDFILL
DAILY WEEKLY MONTHLY 1000
HRS
1. LUBRICATION
1
PACKER
CYLINDER PINS
(4)
X
2
ARM CYLINDER
PINS (2) AND
PIVOTS (2)
X
3
ARM PIVOT
TUBE COLLARS
(8)
X
4
FORK
CYLINDER PINS
(4)
X
5
FORK PIVOT
TUBE COLLARS
(2)
X

12 Part #: 90309
ITEM DESCRIPTION PRE-TRIP AT
LANDFILL
DAILY WEEKLY MONTHLY 1000
HRS
6TAILGATE
HINGE PINS (2) X
7
TAILGATE
CYLINDER PINS
(2) AND
PIVOTS (2)
X
8
TAILGATE
LATCH ROLLER
PINS (2)
X
*9 REAR BODY
HINGE PINS (2) X
*10
SIDE ACCESS
DOOR HINGES
(2)
X
*11
CLEANOUT
DOOR HINGES
(2)
X
**12
PUMP
DRIVE-LINE
U-JOINTS AND
SLIP YOKE (3)
X